Fired Heater Operations · Field Reference
Everything you need
to run it right.
A practical reference for operators and engineers working with fired heaters in refinery service. Procedures, limits, checklists, and the reasoning behind them — in one place.
Version 2.0
17 new pages added — expanded content, interactive quizzes, and performance calculators.
Heat Transfer
Fuel Systems
Loss of Feed
Isolation & PTW
Emissions Monitoring
Burner Maintenance
6 Module Quizzes
4 Calculators
Reference Modules
Overview
Introduction
What fired heaters are, where they sit in the refinery, and why they demand careful operation.
Role in refinery
Heat duty
Key risks
Module 01
Fundamentals
Heater types, combustion, burner design, draft, heat transfer mechanisms, and fuel system operation.
Combustion
Heat transfer
Fuel systems
Draft control
Module 02
Operations
Step-by-step procedures for startup, normal operations, planned shutdown, and decoking runs.
Startup
Normal ops
Shutdown
Decoking
Module 03
Abnormal Operations
Recognising upsets early, flame-out response, tube failure protocol, loss of feed, and emergency shutdown.
Flame-out
Tube failure
Loss of feed
ESD
Module 04
Safety Systems
BMS logic, safety interlocks, pre-startup safety reviews, and isolation and permit-to-work procedures.
BMS
Interlocks
PSSR
Isolation / PTW
Module 05
Performance
Thermal efficiency, stack loss, O₂ trim, emissions monitoring, fouling indicators, and troubleshooting.
Efficiency
Stack O₂
Emissions
Fouling
Module 06
Inspection & Maintenance
Rounds checklists, refractory condition, tube assessment, and burner maintenance procedures.
Rounds
Refractory
Tubes
Burner maint.
Reference
Quick Reference
Operating limits, alarm setpoints, and glossary — everything you'd reach for in a hurry.
Limits table
Glossary
Tools
Assessment
Module Quizzes
Scored 10-question quizzes for each module. Test applied understanding, not just recall — scenario-based questions throughout.
01 Fundamentals
02 Operations
03 Abnormal
04 Safety
05 Performance
06 Inspection
Performance Toolkit
Calculators
Interactive field calculators for thermal efficiency, excess air, tube metal temperature, and heat duty. Indicative results only.
Thermal efficiency
Excess air
Tube metal temp
Heat duty
For Qualified Personnel
This reference uses industry-typical values and generic operating ranges. All procedures and limits must be verified against your site-specific operating manual before use. Not a substitute for formal training or site authorisation.